Safety signaling system for marine engine cooling systems



F. N. JENSEN June 21, 1966 SAFETY SIGNALING SYSTEM FOR MARINE ENGINECOOLING SYSTEMS Filed Sept. 30, 1963 OUTBOARD MOTOR 3,257,643 SAFETYSIGNALING SYSTEM FOR MARINE ENGINE COOLING SYSTEMS Fred N. Jensen, 7805Lake Drive, East St. Louis, Ill. Filed Sept. 30, 1963, Ser. No. 312,5769 Claims. (Q1. 34052) This invention relates to improvements insignaling systems for internal combustion engines with a liquid coolingsystem. Although it is not limited to internal combustion engines, it isparticularly useful with marine engines, inboards and outboards, due tothe hazards they encounter, and are subject to, when in use.

The principal features of this invention may be summarized in threeaspects. First of all the system provides an instant, visual warning ofmalfunction of the cooling system due to interruption of circulation,although audible signals may also be used. As is known, the coolingsystems of marine engines, and particularly outboard engines, have aforced coolant circulation,

forced through the engine cooling system by means of a pump which issubject to wear and breakage. The cooling systems intake lines aresubject to clogging, mud, sand, or picking up of any foreign matter, allof which interrupts the circulation through the cooling system. Uponfailure of the coolant pump, or clogging of the intake lines, in suchfailures, the coolant level is lowered from the top, or highest part, ofthe cooling system. The top or highest part of the cooling system is thelocation of a specially designed sensor with a contacting electrode.This is very important in the operation of this device, as upon loweringof cool-ant in the system, an electrical coolant contact with the sensorelectrode is broken, and immediately upon being broken, a visibleWarning signal indicating failure in the engine cooling system warns ofthis malfunction before serious damage to the engine occurs. Unlikedevices that depend on heat to operate, this device operates on coolantcontact, before damaging heat occurs.

Secondly, the system provides warning that the ignition switch is lefton, with the engine not in use, when this occurs due to operatorsnegligence or otherwise. Some marine engines are stopped by retardingthe throttle, some by their own accord due to mechanical difficulties.When this occurs, failure to turn the ignition switch off with theengine not in use, can be very damaging to the electrical system,battery drain, burned points, overheated resistors, etc. Due to thedesign and operation of this device, the sensor, with its contactingelectrode, located in the top or highest part of the engines coolingsystem, warns of this condition when the ignition switch is left on withthe engine not in use. Also, should the engine stop for any reason,other than by turning off the ignition switch, coolant circulation isstopped, coolant level is lowered in the engine cooling system whichcauses breaking of contact with the sensor element with its contactingelectrode. This in turn activates a warning signal to warn that theignition is left on.

Thirdly, the system warns of signal system malfunction, loose or brokenwires, bulbs burned out or broken. This invention is so designed thateach time the ignition switch is turned on, there must be a red light.When there is no red light, with the ignition on, the operator willcheck the bulb or search for loose or broken wires. In proper systemoperation, when the ignition is on, the red light comes on, the engineis started and coolant circulates through the engine cooling system.When the coolant reaches the top or highest part of the system where thesensor with its contacting electrode is located,

the red light changes to green, indicating the system is full orcoolant. Should the green light not-appear with 3,257,643 Patented June21, 1966 ice the red light out, the operator will be informed that heshould check the bulb or search for loose or broken wires. Thus, at alltimes, with the ignition on, and the engine running, these must be alight to provide assurance of proper operation.

Another feature of this invention resides in the provision of the sensorelement which is connected into the water jacket to place an electrodein contact with the water coolant to provide a ground. This sensor isconnected to the signaling system. The sensor is specially constructedof a carbon electrode and a specially designed and configured Tefloninsulating element which resists water adsorption or chemical damage dueto polluted coolant water to prevent shorting out of the system. The

sensor is quite rugged to withstand heavy duty operation and is simpleto install.

As a consequence of the signaling system of this invention, and theprovided sensor element, the operator will be warned by the red light ofthe signal system, should the ignition key be left on for any length oftime without operation of the engine, should the engine stop for anyreason other than turning off of the ignition key, and is furtherwarned, should water circulation be stopped, or partially blocked. Dueto the location of the sensor element in the water jacket, shouldclogging of the intake water occur, or a failure of the water pumpoccur, the operator is warned by the signal light before the engineoverheats and before damage to the engine occurs, such that the operatorcan immediately turn the engine off and locate the source of the troubleor have any necessary repairs made. The operator is further warned of aweak or worn water pump, e.g., when the red light flicks on and off.

The above features are objects of this invention and further objectswill appear in the detailed description which follows and will beotherwise apparent to those skilled in the art.

For the purpose of illustration of this invention, a preferredembodiment is shown in the drawings. It is to be understood that thesedrawings are for the purpose of example only, however, and that theinvention is not limited thereto.

In the drawings:

FIGURE 1 is a schematic electrical diagram of the sig naling system ofthis invention as connected to an outboard motor;

FIGURE 2 is a view in elevation of the sensor element employed in theinvention;

FIGURE 3 is an enlarged View in vertical section showing theconstruction of the sensor element;

FIGURE 4 is a plan view showing the mounting of the signal lights;

FIGURE 5 is a view in side elevation taken from the right side of FIGURE4 showing the mounting of the signal lights and the mounting of theelements employed in the circuit to the rear of the signal lights andprotected by a dust cap;

FIGURE 6 is a view in section showing the mounting of the sensor elementupon the water jacket of the outboard motor;

FIGURE 7 is an enlarged view showing the dust cap in section and thearrangement of the electrical components of the control system; and

FIGURE 8 is a further view in section taken on the line 8-8 of FIGURE 7.

In FIGURE 1 the schematic electrical diagram is shown and the majorelectrical components of this invention are contained within the controlmounting 10. In addition, external to the components in the controlmounting, are a lead 12, leading to sensor 14, mounted upon water jacket16 of the outboard motor. A second lead 18 is connected externally fromthe control mounting through ignition switch 19 to battery 20, which isgrounded at 22. In addition, a third lead 24 is con nected to a redwarning lamp 28 grounded at 30. A fourth lead 32 is connected to a greennormal operating condition lamp 34 which is grounded at 36.

The control mounting contains as its main components a transistor 48 andelectrical relay 42. The relay is composed of a coil 44 and an armature46. The armature 46 is provided with two contacts, one being a normallyclosed contact 48 in the circuit to the red warning lamp 28, and theother being a normally open contact 58 leading to the green satisfactoryoperating condition lamp 34. A lead '52 connects the armature tojunction point 54.

The transistor 40 is comprised of a base 56, a collector 58, and anemitter 60. The base 56 is connected by lead 62 to a resistor 64, whichis connected to the aforementioned lead 12. Another resistor 66 isconnected between the junction point 54 and the lead 62.

The collector 58 is connected by lead 68 to the coil 44 and is groundedon the other side by lead 78 at ground 22. The emitter 60 is connectedby lead 72 to the junction point 54.

The sensor 14, as best shown in FIGURES 2, 3 and 6, is composed of abrass base or body 74 which has a threaded portion 76 at the lower endso that it may be threaded within the tap hole of the water jacketcasing 16. It has a hexagonal exterior 78 so that it may receive awrench to be tightened into the tap hole. An integral Teflon insulatingshell 80 is received Within a bore of the sensor shell in a press-fittedrelationship, and,

in turn, receives a sensor post 82 constructed of brass.

A carbon electrode 84 is press-fitted within the bottom of the Teflonshell 80. A conductor 88 connects the carbon electrode plug 84 with thesensor terminal post.

It is to be noted that Teflon is employed because of its very highdegree of lack of water adsorption and resistance to salt water andchemicals present in polluted water which are prevalent in industrialWaterways. Other synthetic resins, such as nylon, have some degree ofwater adsorption which contributes to malfunctioning in the sensorelement which thereby shorts out to the metallic water jacket, such asto falsely indicate that the sensor is operating properly even thoughwater has left the water cooling chamber 16. The configuration of thebottom'portion 86 of the shell 80 is also to be noted as having aflaring and downwardly tapering configuration which avoids build-up ofsalt where used in salt water and other foreign matter which occurs in acylindrical configuration. Due to this configuration the coolant waterreadily drips off the sensor when the engine is stopped, therebyminimizing the possibility of attack and seepage into the sensor betweenthe insulating shell and the electrode plug.

The sensor element 14 is best shown connected to the water jacket 16 ofa typical outboard engine in FIGURE 6. As there shown, it is seen thatthe threaded portion 76 of the sensor element is readily received withina tap hole 90. The carbon electrode plug is positioned in the top of thewater cooling chamber 92, but spaced from the inside wall 94. Bypositioning at the top of the chamber, ready indicating of anymalfunctioning of the Water pump or partial draining of the watercoolant is immediately indicated, as this is the first part of thejacket drained of water.

FIGURE 4 shows a mounting plate 96 for the mounting of the red safetylight 28 and the green light 34. The plate 96 also receives a threadedand hollow mounting socket 98 which is connected at the back to amounting plate 100 which receives the electrical components of thecontrol mounting. A dust cap 102 acts to protect the components from anydamage. The electrical components previously described in the controlmounting 10 are simply mounted upon the mounting plate and are readilyavailable for any repair or checking of action by removal of the dustcap.

The arrangement of the electrical components in FIGURES 5, 7 and 8 showsthe ready mounting upon the mounting plate 180. Thus, the electricalrelay 42 is simply mounted upon the mounting plate as is the transistor40. Likewise, the resistors 64 and 66 are simply connected into thecircuit. The armature 46, adapted to make and break contact withcontacts 48 and 50, are readily accessible once the dust cap 102 isremoved, such that any required repair or maintenance is easilyprovided.

OPERATION The operation of the safety signal system of this invention isquite simple. As the operator turns on the ignition key 19 to close theswitch, the normally closed contact 48 creates a circuit from thebattery 20, through junction point 54, lead 52, the armature 46, theignition switch, and the red light 28, which is grounded at 30. Thisindicates to the operator that the switch is on but that the coolingsystem is not operating.

As the engine is started, water is caused to circulate through thecooling space 92 and the cooling jacket 16. As this occurs, theelectrode 84 is grounded through the water to the grounded enginejacket. In this condition the transistor 40 will conduct. The transistorpasses current through the coil 44 of the relay to close the armatureagainst the normally open contact 58. This causes the breaking of thecircuit to the red light and the red light goes out, and, since thecircuit is now made to the green light 34, this light will go onindicating satisfactory operation.

Should the water pump .be damaged, or should the water intake beclogged, or for any other reason, should water not satisfactorilycirculate through the chamber 92, the grounding condition will beremoved when water leaves the top of the chamber. When this occurs, anopening is created in the circuit to the transistor causing the relay toreturn to its normal position, i.e., to close the contact 46 against thecontact 48. This, of course, causes the green light to go out and thered light to return. Upon the indication of the red light, the operatorwill be informed of a malfunction and any necessary repair can beeffected.

Accordingly, there has been provided a safety signaling system which canbe employed by an outboard engine operator to insure that the coolingsystem is operating properly. The protection of the engine is therebyafforded immediately upon the indication of unsatisfactory operation ofthe cooling system. Through the provision of the sensor element, a veryrugged and efiiciently operating element has been provided. Likewise,through the arrangement of the mounting of the electrical components inthe control mounting with the readily removable dust cap, easy repairand maintenance, should this be necessitated, is afforded.

Various changes and modifications may be made within this invention aswill be readily apparent to those skilled in the art. Such changes andmodifications are within the scope and teaching of this invention asdefined by the claims appended hereto.

What is claimed is:

1. A signaling system for marine engines to indicate the condition of anelectrical ignition system and a water coolant system employed in theengine, said system employing a first circuit operative when an ignitionswitch is turned on to energize a warning light to indicate that theignition is on and that coolant is not being circulated through thecoolant system, and a second circuit including a sensor elementestablished by the circulation of water through the coolant system whenin contact with the sensor element to provide a short circuiting groundto the engine, thereby energizing a relay to open the first circuit andestablish a connection to a second light indicating satisfactoryoperation of said coolant system.

' the condition of an electrical ignition system and a water coolantsystem employed in the engine, said system employing a first circuitoperative when an ignition switch is turned on to energize a warninglight to indicate that the ignition is on and that coolant is not beingcirculated through (the coolant system, and a second circuit including asensor element and a transistor acting as a switch to conduct current,established by the circulation of water through the coolant system whenin contact with the sensor element to provide a short circuiting groundto the engine, thereby energizing a relay to open the first circuit andestablish a connection to a second light indicating satisfactoryoperation of said coolant system.

3. A signaling system for marine engines to indicate the condition of anelectrical ignition system and a water coolant system employed in theengine, said system employing a first circuit operative when an ignitionswitch is turned on to energize a warning light to indicate that theignition is on and that coolant is not being circulated through thecoolant system, and a second circuit including a sensor elementestablished by the circulation of water through the coolant system whenin contact with the sensor element to provide a short circuiting groundto the engine, thereby energizing a relay to open the first circuit andestablish a connection to a second light indicating satisfactoryoperation of said coolant system, said sensor comprising a brass bodycontaining an insulated carbon electrode adapted to be inserted in theshell of a water jacket with the electrode in communication with thecoolant inside said shell, said electrode being insulated from saidshell by a Teflon insulating element characterized by its lack of wateradsorption and resistance to attack by brine and other chemicals.

4. A signaling system for marine engines to indicate the condition of anelectrical ignition system and a water coolant system employed in theengine, said system employing a first circuit operative when an ignitionswitch is turned on to energize a warning light to indicate that theignition is on and that coolant is not being circulated throughthecoolant system, and a second circuit including a sensor element and atransistor acting as a switch to conduct current, established by thecirculation of water through the coolant system when in contact with thesensor element to provide a short circuiting ground to the engine,thereby energizing a relay to open the first circuit and establish aconnection to a second light indicating satisfactory operation of saidcool-ant system, said signaling system containing as a separate mountingunit the relay and said transistor mounted upon a mounting plate andprotected by a removable cap whereby the mounting unit may be simplyconnected to the ignition system of said marine engine as a unit.

5. A signaling system for marine engines to indicate the condition of anelectrical ignition system and a water coolant system employed in theengine, said system employing a first circuit operative when an ignitionswitch is turned on to energize a warning light to indicate that theignition is on and that coolant is not being circulated through thecoolant system, and a second circuit including a sensor element and atransistor acting as a switch to conduct current, established by thecirculation of water through the coolant system when in contact with thesensor element to provide a short circuiting ground to the engine,thereby energizing a relay to open the first circuit and establish aconnection to a second light indicating satisfactory operation of saidcoolant system, said signaling system containing as a separate mountingunit the relay and said transistor mounted upon a mounting plate andprotected by a removable cap whereby the mounting unit may be simplyconnected to the ignition system of said marine engine as a unit, saidmounting plate being connected to a separate light mounting platesupporting the aforementioned lights whereby the lights, the relay, andthe transistor may be installed as a unit.

6. A signaling system for marine engines to indicate the condition of anelectrical ignition system and a water coolant system employed in theengine, said system employing a first circuit operative when an ignitionswitch is turned on to energize a warning light to indicate that theignition is on and that coolant is not being circulate-d through thecoolant system, and asecond circuit including a sensor element and atransistor acting as a switch to conduct current established by thecirculation of water through the coolant system when in contact with thesensor element to provide a short circuiting ground to the engine,thereby energizing a relay to open the first circuit and establish aconnection to a second light indicating satisfactory operation of saidcoolant system, said sensor comprising a brass body containing aninsulated carbon electrode adapted to be inserted in the shell of aWater jacket with the electrode in communication with the coolant insidesaid shell, said electrode being insulated from said shell by a Tefloninsulating element characterized by its lack of water adsorption, saidsignaling system containing as a separate mounting unit the relay andsaid transistor mounted upon a mounting plate and protected by aremovable cap whereby the mounting unit may be simply connected to theignition system of said marine engine as a unit.

7. A signaling system for marine engines to indicate the condition of anelectrical ignition system and a water coolant system employed in theengine, said system employing a first circuit operative when an ignitionswitch is turned on to energize a warning light to indicate that theignition is on and that coolant is not being circulated through thecoolant system, and a second circuit including a sensor elementestablished by the circulation of water through the coolant system whenin contact with the sensor element to provide a short circuiting groundto the engine, thereby energizing a relay to open the first circuit andestablish a connection to a second light indicating satisfactoryoperation of said coolant system, said sensor comprising a brass bodycontaining an insulated carbon electrode adapted to be inserted in theshell of a water jacket with the electrode in communication with thecoolant inside said shell, said electrode being insulated from saidshell by a Teflon insulating element characterized by its lack of wateradsorption, said Teflon insulating element being in the form of a shellenclosing the electrode in exposed relation at one end and supported tothe brass body at the other end, and a connector connecting saidelectrode with a mounting terminal at an opposite end of the brass body,and said Teflon insulating element shell having an exterior surfacediverging generally from the exposed end of said electrode to adjacentthe connection with said brass body.

8. A sensor element for use with marine engines to establish a shortingcondition in a coolant jacket employed therein, said sensor comprising abrass body containing an insulated carbon electrode adapted to beinserted in the shell of a water jacket with the electrode incommunication with the coolant inside said shell, said electrode beinginsulated from said shell by a Teflon insulating element characterizedby its lack of water adsorption and resistance to chemical attack bybrine and other chemicals, said Teflon shell serving to protect theelectrode and being substantially flush with the end of the electrode.

9. A sensor element for use with marine engines to establish a shortingcondition in a coolant jacket employed therein, said sensor comprising abrass body containing an insulated carbon electrode adapted to beinserted in the shell of a water jacket with the electrode incommunication with the coolant inside said shell, said electrode beinginsulated from said shell by a Teflon insulating element characterizedby its lack of water adsorption and resistance to chemical attack bybrine and other chemicals, said Teflon insulating element being in theform of a shell enclosing the electrode in exposed 7 8 relation at oneend and supported to the brass body at ReferencesCited by the Examinerthe other end and a connector connecting said electrode UNITED STATESPATENTS with a mounting termlnal at an opposite end of the brass body,and said Teflon insulating element shell having an 11/1941 E'WertZ Xexterior surface diverging generally from the exposed 5 2,385,161 9/1945Pmkerton 34O-244 X end of said electrode to adjacent the connection withsaid 2,477,511 7/1949 Combbrass body, said Te-fion shell serving toprotect the electrode and being substantially flush with the end of theNEIL READ p'lmary Exammer' electrode. A. WARING, Assisttmt Examiner.

1. A SIGNALING SYSTEM FOR MARINE ENGINES TO INDICATE THE CONDITION OF AN ELECTRICAL IGNITION SYSTEM AND A WATER COOLANT SYSTEM EMPLOYED IN THE ENGINE, SAID SYSTEM EMPLOYING A FIRST CIRCUIT OPERATIVE WHEN AN IGNITION SWTICH IS TURNED ON THE ENERGIZE A WARNING LIGHT TO INDICATE THAT THE IGNITION IS ON AND THAT COOLANT IS NOT BEING CIRCULATED THROUGH THE COOLANT SYSTEM, AND A SECOND CIRCUIT INCLUDING A SENSOR ELEMENT ESTABLISHED BY THE CIRCULATION OF WATER THROUGH THE COOLANT SYSTEM WHEN IN CONTACT WITH THE SENSOR ELEMENT TO PROVIDE A SHORT CIRCUITING GROUND TO THE ENGINE, THEREBY ENERGIZING A RELAY TO OPEN THE FIRST CIRCUIT AND ESTABLISH A CONNECTION TO A SECOND LIGHT INDICATING SATISFACTORY OPERATION OF SAID COOLANT SYSTEM. 